Box with pour spout

ABSTRACT

A box is folded from a paperboard blank and has a spout along one side of the box formed by two layers of the blank laminated together. The layers are connected to overlapping panels, at opposite ends of the blank, by aligned fold lines. The flaps of the inner spout layer can also have hold-open and hold-closed notches formed in them, and a vapor barrier can be provided. The spout and container form a labyrinth seal such when the spout is closed the spout inner layer and the inner panel are substantially coplanar and the spout outer layer and the outer panel are substantially coplanar and an edge of the spout inner layer abuts an edge of the inner panel at a location between the first fold line and an edge of the spout outer layer opposite the first fold line.

CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims priority to U.S. provisional application Ser. No. 60/324,385 filed Sep. 24, 2001.

STATEMENT CONCERNING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

[0002] Not applicable.

FIELD OF THE INVENTION

[0003] This invention relates to boxes with pour spouts of the type that are typically used for containing and dispensing pourable product such as powdered soap, rice, cereal and like materials.

BACKGROUND OF THE INVENTION

[0004] Closeable pour spouts have been used in paperboard containers. In many cases, the pour spout itself has been a different material, such as metal or plastic, although paperboard pour spouts have also been used.

[0005] It is desirable that pour spout boxes have a lock or detent into the position of pouring and also lock when closed. The pour spout should provide for complete emptying of the container and also should not leak, should be generally vapor and liquid impermeable and should be sift proof when it is closed. It is also desirable that the pour spout be easy to open, be tamper evident and be durable for the number of uses typically necessary to empty the container. The container and pour spout, being a disposable item, must also be inexpensive to manufacture and completely and inexpensively recyclable.

SUMMARY OF THE INVENTION

[0006] The present invention provides a container having a pour spout which satisfies the above needs. A container of the invention includes a one piece paperboard sheet folded and glued so as to make the container. The sheet has two panels at opposite ends which overlap so that one panel is on the outside of the container and one other is on the inside. The outer panel has a spout outer layer cut into it which is connected to the one panel by a first fold line. The inner panel has a spout inner layer cut into it which is connected to the inside panel by a second fold line. The first and second fold lines lie in substantial registration with one another and the inner and outer spout layers are laminated together so that the laminated spout layers pivot about the first and second fold lines to open and close the spout. This provides an inexpensive to make and completely recyclable container.

[0007] In a preferred aspect, at least one side of the outer spout layer has cuts offset from one another and only partially through the material thickness of the outer spout layer. This holds the spout closed until it is first opened, and provides a tamper evident seal.

[0008] In another useful aspect, the inner spout layer includes flaps folded inwardly from a center panel of the inner spout layer which is laminated to the outer spout layer. The flaps extend into the interior of the container and form the sides of the spout when it is open. At least one of the flaps can have a hold-open notch, a hold-closed notch or both formed in it.

[0009] In another preferred aspect, the spout is adjacent to a side of the container. This feature contributes to easier emptying of the container, since the last bit of product in the container can be collected on the sidewall of the container which is adjacent to the spout by tipping the container so it collects on that side, and then poured out through the spout. Alternatively, the pour spout can be centered between opposite side edges of the end wall of the container.

[0010] In another preferred aspect, the invention provides a vapor barrier layer covering an outside surface of the container including the pour spout. The vapor barrier layer can be a film or a chemical finish applied to the paperboard sheet.

[0011] In still another preferred aspect, the container and the pour spout form a labyrinth seal in which spout inner layer and the inner panel are substantially coplanar and the spout outer layer and the outer panel are substantially coplanar and an edge of the spout inner layer abuts an edge of the inner panel at a location between the first fold line and an edge of the spout outer layer opposite the first fold line when the spout is closed. This requires air, vapor or container contents to pass around a ninety degree path to enter or escape from the container, thereby provide a tight seal, particularly when used in conjunction with a vapor barrier.

[0012] The foregoing and other objects and advantages of the invention will appear in the detailed description which follows. In the description, reference is made to the accompanying drawings which illustrate a preferred embodiment of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0013]FIG. 1 is a perspective view of a folded and glued paperboard container incorporating a pour spout of the invention;

[0014]FIG. 2 is detail view of the spout of FIG. 1, shown opened;

[0015]FIG. 3 is a plan view of the unfolded blank for making the paperboard container of FIGS. 1 and 2;

[0016]FIG. 4 is a cross-sectional view from the plane of the line 4-4 of FIG. 1;

[0017]FIG. 5 is a cross-sectional view from the plane of the line 5-5 of FIG. 2;

[0018]FIG. 6 is a cross-sectional view from the plane of the line 6-6 of FIG. 1;

[0019]FIG. 7 is a cross-sectional view from the plane of the line 7-7 of FIG. 3;

[0020]FIG. 8 is a view like FIG. 4 but showing an embodiment with a vapor barrier layer; and

[0021]FIG. 9 is a plan view of the unfolded blank for making an alternate paperboard container having a pour spout centered on an end wall.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0022] Referring particularly to FIGS. 1 and 3, a box 10 of the invention is folded from a cut and scored one piece sheet blank 12, for example which may be made out of paperboard or other similar sheet material. The box 10 and blank 12 have panels 14, 16, 18, 20 and 24 which define the side walls, by panels 16 and 20, and the end walls, by panel 18 and overlapping panels 14 and 24 at opposite ends of the blank, at the ends of the box 10. As shown in FIG. 3, each panel 14, 16, 18, 20 and 24 has respective end flaps 26, 28, 30, 32 and 34 at its opposite ends and which overlap flaps of the other panels.

[0023] When folded, end panel 24 overlaps end panel 14, with glue areas 36 illustrated in FIG. 3 on the outside of panel 14 (inside of panel 24) laminating the two panels together. The flaps 26, 30 and 34 of the end walls are folded beneath the flaps 28, with the flaps 26 outside of the flaps 34, and the flaps 32 are folded down on top of the flaps 28 and adhered to the flaps 28.

[0024] At the end wall of the box 10 that has the pour spout 40 formed in it, the end wall is formed by both end panels 14 and 24. End panel 14 is the inside panel and end panel 24 is the outside panel. Each panel 14 and 24 has a spout layer cut into it, the inner spout layer formed in panel 14 being identified by 42, and the outer spout layer 44 being cut into panel 24. Inner spout layer 42 has a center or main panel 46 and side panels 48 and 50 attached to the sides of the center panel 46 by a fold line 51 or 53 at the corner joint between the center panel 46 and the respective side 48 or side 50. Center panel 46 is also joined at its base to the remainder of panel 14 by a fold line 52. Fold line 52 is in registration with fold line 54 which joins the base of outer spout layer 44 to the remainder of the panel 24.

[0025] The spout and container form a labyrinth seal which requires air, moisture or the contents of the box to travel through a bend of approximately 90° to pass between the pour spout 40 and the end panels 14 and 24, thus providing a significant physical barrier between the container contents and the outside. In particular, as can be seen in FIG. 4, when the spout 40 is closed the central panel 46 of the inner spout layer 42 is substantially coplanar with the panel 14 as are the outer spout layer 44 and panel 24. A top edge 55 of the central panel 46 of the inner spout layer 42 abuts an edge 67 of panel 14 at a location vertically between the fold lines 52 and 54 and a top edge 59 of the spout outer layer 44 opposite fold line 54. An upper end portion 47 of the outer layer 44 overlaps the butt joint between edges 55 and 67 to provide additional sealing by making the entry/exit path labyrinthine.

[0026] The left and top sides (as viewed in FIG. 3) of the panel 44 are cut all the way through the thickness of the panel 24, and a crescent shaped hole 57 is cut out at the top of the panel 44 to allow a person to stick their finger or fingernail behind the panel 44 to open it. The right side of the panel 44 (as viewed in FIG. 3) is formed by two fifty-percent cuts 60 and 62, one on the inside surface and one on the outside surface, parallel and spaced apart so that they are offset from one another, as shown in FIGS. 3 and 7. Each cut 60, 62 goes only about halfway through the material thickness. Since the material is not completely broken through at the right side, this holds the spout shut until the package is first opened. When the package is opened by a person sticking their finger or fingernail into the hole 57 to pry open the spout, the material between the inner ends of the two cuts 60 and 62 fractures, permitting opening of the spout, including both the outer panel 44 and the inner layer 42.

[0027] It is noted that a glue spot 36 exists between the outer surface of the center panel 46 and the inner surface of the outer spout layer 44 which laminates the two layers 44, 46 together. Other glue areas 36 are provided outside of the spout layer 42 between the panels 14 and 24, to seal the box. Thus, the spout 40 is actually comprised of two layers, each layer having its own hinge line 52 or 54, and both hinge lines being in registration with one another when the box is assembled. In spite of the fact that there is a double layer of material, since the material is paperboard, there is sufficient give in the material to permit hinging about the fold lines 52 and 54, although there is a desirable tendency of the box and memory of the material to hold the spout most of the way shut.

[0028] The flaps 48 and 50 of the inner spout layer 42 are folded inwardly from the central panel 46 and extend from the panel 14 into the inside of the box, when the spout is shut. Panel 48, as shown in FIG. 6, is spaced from both side walls of the box, and panel 50 is adjacent to the side wall 20. Panel 50 has a hold-closed notch 64 cut into its upper edge and a hold-open notch 66 also cut into its upper edge. The hold-closed notch 64 engages the upper edge 67 of the hole from which the spout is cut to hold the spout closed, as shown in FIG. 4. The hold-open notch 66 engages the same edge 67 to hold the spout open, as shown in FIG. 5. A user therefore does not need to hold the spout open as will it hold itself open, and also the spout will hold itself closed when a user closes it. There is sufficient resiliency in the paperboard material so that the notches 64 and 66 can withstand repeated openings and closings and still function. The paperboard material used may, for example, be a poly-coated stock, a UV-coated stock or a poly-coated/UV-coated paperboard stock.

[0029] The side mounting of the spout 40 makes it easier to completely empty the contents of the box 10. In addition, since the sides of the spout are closed by the flaps 48 and 50, the spout is sift proof, meaning that leakage is very small or non-existent. In addition, when the spout is closed, the front wall of the spout is flush with the interior walls of the carton for easier product loading, which is generally from the top of the box. The spout having the fifty percent cuts along the laterally inside edge, which may be referred to as being nicked in, also provides a tamper evident seal, while being easy to open.

[0030] As shown in FIG. 8, a container of the invention could be wrapped in a foil or poly wrap layer 80 to provide a moisture or vapor barrier to enclose the contents of the container, and also a reflective or otherwise eye-catching surface on which to provide graphics. The layer 80 preferably covers the spout 40, and instructions for opening can be provided on the outside of the layer 80 for opening the spout such as “Insert finger here and pull down and forward to open spout”, with “here” being at the cut-out 57. The layer 80 may be unadhered to the paperboard material of the container, or may be laminated or otherwise adhered to it.

[0031]FIG. 9 shows an unfolded blank for making an alternate paperboard container having a pour spout centered on an end wall. This embodiment of the invention is nearly identical to the above described embodiment with the primary exception of the centered location of the pour spout. As such, the figures of the above described embodiment should be referenced for details not specifically shown in this embodiment. Also, elements in this embodiment similar to those in the above described embodiment will be referenced herein using similar reference numbers, albeit with the suffix “A”.

[0032] Referring to FIG. 9, a box 10A of the invention is folded from a cut and scored one piece, preferably paperboard, sheet blank 12A having panels 14A, 16A, 18A, 20A and 24A. Panels 16A and 20A define opposite side walls of the box 10A and panel 18A and overlapping panels 14A and 24A define opposite end walls of the box 10A. Panels 16A, 18A, 20A and 24A each have respective end flaps 28A, 30A, 32A and 34A at their opposite ends and which overlap flaps of the other panels. Like above, when folded, end panel 24A overlaps end panel 14A, with adhesive applied at areas 36A having spaced partial slits on the outside of panel 14A (inside of panel 24A) laminating the two panels together. The flaps 30A and 34A of the end walls are folded beneath the flaps 28A and the flaps 32A are folded down on top of, and adhered to, the flaps 28A.

[0033] At the end wall of the box 10A that has the pour spout 40A formed in it, the end wall is formed by both end panels 14A and 24A. End panel 14A is the inside panel and end panel 24A is the outside panel. Each panel 14A and 24A has a spout layer cut into it, the inner spout layer formed in panel 14A being identified by 42A, and the outer spout layer 44A being cut into panel 24A. Inner spout layer 42A has a center or main panel 46A and side panels 48A and 50A attached to the sides of the center panel 46A by a fold line 51A or 53A at the corner joint between the center panel 46A and the respective side 48A or side 50A. Center panel 46A is also joined at its base to the remainder of panel 14A by a fold line 52A. Fold line 52A is in registration with fold line 54A which joins the base of outer spout layer 44A to the remainder of the panel 24A.

[0034] Like above, the spout and container form a labyrinth seal (as shown in FIG. 4) such that when the spout 40A is closed the central panel 46A of the inner spout layer 42A is substantially coplanar with the panel 14A as are the outer spout layer 44A and panel 24A. A top edge 55A of the central panel 46A of the inner spout layer 42A abuts the facing edge of panel 14 a at a location vertically between the fold lines 52A and 54A and a top edge 59A of the spout outer layer 44A opposite fold line 54A, so that the upper portion of layer 44A overlaps the butt joint at edge 55A.

[0035] The top side of the panel 44A is cut all the way through the thickness of the panel 24A, and a crescent shaped hole 57A is cut out at the top of the panel 44A to allow a person to stick their finger or fingernail behind the panel 44A to open it. The left and right sides of the panel 44A are each formed by two fifty-percent nick cuts (such as cuts 60 and 62 in FIG. 7), one on the inside surface and one on the outside surface, parallel and spaced apart so that they are offset from one another. Since the material is not completely broken through at the right side, this holds the spout shut until the package is first opened. When the package is opened by a person sticking their finger or fingernail into the hole 57A to pry open the spout, the material between the inner ends of the two nick fractures, permitting opening of the spout, including both the outer panel 44A and the inner layer 42A.

[0036] Like above, a glue spot 36A exists between the outer surface of the center panel 46A and the inner surface of the outer spout layer 44A which laminates the two layers 44A, 46A together. Other partially slit glue areas 36A are provided outside of the spout layer 42A between the panels 14A and 24A, to seal the box. Thus, the spout 40A is actually comprised of two layers, each layer having its own hinge line 52A or 54A, and both hinge lines being in registration with one another when the box is assembled. In spite of the fact that there is a double layer of material, since the material is paperboard, there is sufficient give in the material to permit hinging about the fold lines 52A and 54A, although there is a desirable tendency of the box and memory of the material to hold the spout most of the way shut.

[0037] Like above, the flaps 48A and 50A of the inner spout layer 42A are folded inwardly from the central panel 46A and extend from the panel 14A into the inside of the box, when the spout is shut. In this embodiment, both panels 48A and 50A are spaced from both side walls 16A and 20A of the box. Panel 50A has a hold-closed notch 64A cut into its upper edge and a hold-open notch 66A also cut into its upper edge; the notches function as described above and shown FIGS. 4 and 5.

[0038] Also like above, the paperboard material used may, for example, be a poly-coated stock, a UV-coated stock or a poly-coated/UV-coated paperboard stock. Or, the box could be wrapped in a foil or poly wrap layer either unadhered to the paperboard, or laminated or otherwise adhered to it as desired.

[0039] Preferred embodiments of the invention have been described in considerable detail. Many modifications and variations to these embodiments will be apparent to those skilled in the art. Therefore, the invention should not be limited to these embodiments, but should be defined by the claims which follow. 

What is claimed is:
 1. A container having a pour spout, comprising: a one piece paperboard sheet folded and glued so as to make the container, wherein, the sheet has two panels which overlap, one panel on the outside of the container and one on the inside, the outer panel being at one end of the sheet and having a spout outer layer cut into it, the spout outer layer connected to the outer panel by a first fold line, the inside panel being at an end of the sheet opposite the outside panel and having a spout inner layer cut into it, the spout inner layer connected to the inside panel by a second fold line, wherein the first and second fold lines lie in substantial registration with one another; and the inner and outer spout layers are laminated together so that the laminated spout layers pivot about the first and second fold lines.
 2. The container of claim 1, wherein at least one side of the outer spout layer has cuts offset from one another and only partially through the material thickness of the outer spout layer.
 3. The container of claim 2, wherein the cuts are on opposite surfaces of the outer spout layer.
 4. The container of claim 1, wherein the inner spout layer includes flaps folded inwardly from a center panel of set inner spout layer which is laminated to the outer spout layer.
 5. The container of claim 4, wherein at least one of the flaps has a hold-open notch formed in it.
 6. A container of claim 4, wherein at least one of the flaps has a hold-closed notch formed in it.
 7. The container of claim 1, wherein the spout is adjacent to a side of the container.
 8. The container of claim 1, wherein the spout is spaced from opposite side edges of the panels.
 9. The container of claim 1, further comprising a vapor barrier layer covering an outside surface of the container including the pour spout.
 10. The container of claim 9, wherein the vapor barrier layer is a film applied to the paperboard sheet.
 11. The container of claim 9, wherein the vapor barrier layer is a coating applied to the paperboard sheet.
 12. The container of claim 1, wherein the outer panel defines a finger cut-out adjacent an edge of the spout outer layer opposite the first fold line.
 13. The container of claim 1, wherein the spout inner layer and the inner panel are substantially coplanar and the spout outer layer and the outer panel are substantially coplanar when the spout is in a closed position.
 14. The container of claim 15, wherein the container and the pour spout form a labyrinth seal in which an edge of the spout inner layer abuts an edge of the inner panel at a location between the first fold line and an edge of the spout outer layer opposite the first fold line.
 15. A container having a pour spout, comprising a one piece paperboard sheet folded and glued so as to make the container and define a pour spout cut into a wall of the container having an inner panel and an outer panel, wherein the pour spout is comprised of a spout outer layer connected to the outer panel by a first fold line and a spout inner layer connected to the inner panel by a second fold line in substantial registration with the first fold line so that the pour spout can pivot about the fold lines between a closed position and an open position in which contents in the container can be expelled through the pour spout, wherein at least a portion of the spout inner layer and the inner panel are substantially coplanar and at least a portion of the spout outer layer and the outer panel are substantially coplanar when the spout is in a closed position.
 16. The container of claim 15, wherein the outer and inner panels are located at opposite edges of the paperboard sheet.
 17. The container of claim 15, wherein the inner spout layer includes flaps folded inwardly from a center panel of set inner spout layer which is laminated to the outer spout layer.
 18. The container of claim 17, wherein one flap has a hold-open notch formed in it and the other flap has a hold-closed notch formed in it.
 19. The container of claim 15, wherein the spout is adjacent to a side of the container.
 20. The container of claim 15, wherein the spout is spaced from opposite side edges of the panels.
 21. The container of claim 15, further comprising a vapor barrier layer covering an outside surface of the container including the pour spout.
 22. The container of claim 15, wherein the outer panel defines a finger cut-out adjacent an edge of the spout outer layer opposite the first fold line.
 23. The container of claim 15, wherein side edges of the spout outer layer are defined by nick cuts extending only partially through the outer panel.
 24. The container of claim 15, wherein the container and the pour spout form a labyrinth seal in which an edge of the spout inner layer abuts an edge of the inner panel at a location between the first fold line and an edge of the spout outer layer opposite the first fold line.
 25. A container having a pour spout, comprising a one piece paperboard sheet folded and glued so as to make the container and define a pour spout cut into a wall of the container having an inner panel and an outer panel, wherein the pour spout is comprised of a spout outer layer connected to the outer panel by a first fold line and a spout inner layer connected to the inner panel by a second fold line in substantial registration with the first fold line so that the pour spout can pivot about the fold lines between a closed position and an open position in which contents in the container can be expelled through the pour spout, wherein the container and the pour spout form a labyrinth seal in which an edge of the spout inner layer abuts an edge of the inner panel at a location between the first fold line and an edge of the spout outer layer opposite the first fold line.
 26. The container of claim 25, wherein the outer and inner panels are located at opposite edges of the paperboard sheet.
 27. The container of claim 25, wherein the inner spout layer includes flaps folded inwardly from a center panel of set inner spout layer which is laminated to the outer spout layer.
 28. The container of claim 27, wherein one flap has a hold-open notch formed in it and the other flap has a hold-closed notch formed in it.
 29. The container of claim 25, wherein the spout is adjacent to a side of the container.
 30. The container of claim 25, wherein the spout is spaced from opposite side edges of the panels.
 31. The container of claim 25, further comprising a vapor barrier layer covering an outside surface of the container including the pour spout.
 32. The container of claim 25, wherein the outer panel defines a finger cut-out adjacent an edge of the spout outer layer opposite the first fold line.
 33. The container of claim 25, wherein side edges of the spout outer layer are defined by nick cuts extending only partially through the outer panel.
 34. The container of claim 25, wherein the spout inner layer and the inner panel are substantially coplanar and the spout outer layer and the outer panel are substantially coplanar when the spout is in a closed position. 